Fleet Weigh Installation GuideStep by step guide to installing and configuring Fleet Weigh.

Contents

Calibration of Weight Gauge 3Calibration of Pre Start Checklist 4Calibration of Card Reader 5Calibration of Overspeed Alarm 6Calibration of Seatbelt Interlock 7Wiring Installation 8

Start Up the Unit

For the unit to start up, it must have power (Red 12V and Black Earth), plus an earth on the Orange/White wire.

GroUnd the Green Wire to enter Calibration Mode

To get any response from the weight gauge it first must be calibrated. This is done by earthing the Green wire (Grey plug pin 4). After the green wire is earthed you should see this, Press RED “SELECT” button to configure the weight gauge.

SeleCt the CorreCt SenSor inpUt Channel

Next, press Green button to “CHANGE” to either “Analog Input1” or “Analog Input2” and “SELECT”. 2 Wire 4..20 mA Sensor = Select Analog Input 23 Wire Voltage Sensor = Select Analog Input 1

Set the no load MiniMUM referenCe ValUe

Start the fork truck, raise the tynes and lower them slightly to remove any hydraulic pressure lock, and ensure that they are not resting on the ground. Then press “SET”.

Set the tyneS at fUll load ValUe (MaxiMUM preSSUre ValUe)

Raise the tynes until they top out, Continue to drive the tynes upwards by keeping the lift valve open and the engine revving and press ‘Set’ for Tynes at Full Load. press “SET”.

poUndS or KiloGraMS? SeleCt and Set the deSired UnitS.

Calibrate a KnoWn WeiGht

Pick up a known weight with the tynes and raise to the correct stage of the mast that you wish to weigh at (some forklifts have a multistage mast which means the weight calibration will only be correct for a particular lift height range). Select the known weight amount using the middle directional ‘mouse’ button; UP/DOWN to change the number dramatically and use LEFT/RIGHT to change the number slightly. Then press ‘Set’

SeleCt yoUr readoUt reSolUtion

Change the resolution to set the smallest change in value of the displayed weight, recommended at no lower than about 50, or 100 units. This is useful to stop the displayed weight from varying whilst the vehicle is moving. Use the ‘mouse’ button to adjust, UP/DOWN and LEFT/RIGHT as explained above in 7.

do yoU reqUire an oVerload alarM?

a) Select Yes or No.

b) Select the percentage of maximum load for the Alarm using the ‘mouse’ button.

C) Select how many seconds overloaded before the alarm goes off.

yoU’re done! to operate yoUr WEIGHT GAUGE:

Remove the Green wire from ground, tape up and hide away. This will return the weight gauge to normal opera-tion. During operation press the middle “ZERO” button to set the zero point of the gauge. This is useful when determining the weight difference of multiple loads. Remember to “ZERO” again when tynes are unloaded to go back to normal operation. Always ensure you weigh your load at the correct mast stage, stabilise the load to get a good reading, and slightly lower the load to release any hydraulic pressure locks.

Calibration of Weight Gauge

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Start Up the Unit

For the pre start checklist to start up, it must have power (Red 12V and Black Earth), plus an earth on the Or-ange/White wire.

GroUnd the Green Wire to enter Calibration Mode

To get any response from the pre start check list it first must be enabled and set up. This is done by earthing the Green wire (Grey plug pin 4). After the green wire is earthed you should see this, Press RED “SELECT” button to set up pre start check list.

enable the pre Start CheCkliSt

SeleCt hoW often the pre Start CheCkliSt qUeStionS are aSked

This can be every time the vehicle is started, or up to once every 24hours.

If also using a proximity card reader, the pre start check list can be set to “Every Operator”. This special case lets the pre start checklist start up each time a new card is swiped within the defined time period.

alWayS “load” defaUlt qUeStionS UnleSS they have been CUStoMiSed USinG a pda or laptop, in WhiCh CaSe preSS “next”.

yoU’re done! to operate yoUr pre Start CheCkliSt:

Remove the Green wire from ground, tape up and hide away. This will return the pre start checklist to normaloperation. Remember the vehicle will not be allowed to start until the questions have been completed.

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Calibration of Pre Start Checklist

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Start Up the Unit

For the card reader interlock unit to start up, it must have power (Red 12V and Black Earth), plus an earth on theOrange/White wire.

GroUnd the Green Wire to enter Calibration Mode

To get any response from the card reader interlock unit it first must be set up. This is done by earthing theGreen wire (Grey plug pin 4). After the green wire is earthed you should see this, Press RED “SELECT” button toconfigure the over card reader interlock unit.

enable the Card reader

Store Valid CardS into the Unit

4 a) Select a ‘card slot’ for any particular card number, start at slot 0. There are 512 card slots available for use.Use the middle button “LEFT” and “RIGHT” to increase and decrease the number by 1.Use the middle button “UP” and “DOWN” to increase and decrease the number by 20.

Swipe card over the proximity card reader, the card’s number will appear, this card number is now stored in the selected slot. Select the next card slot and repeat this process.

4 b) Alternatively, manually input the desired card number by pressing the green “MANUAL” button.Now use the middle button to input the desired card number.

YoU’re done! to operate YoUr Card reader:

Remove the Green wire from ground, tape up and hide away. This will return the monitor to normal operation.Start up the unit and swipe card, this will disable the cut-out relay, now the vehicle will be allowed to start(crank).

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Calibration of Card Reader

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Start Up the Unit

For the speed display to start up, it must have power (Red 12V and Black Earth), plus an earth on the Orange/White wire.

GroUnd the Green Wire to enter Calibration Mode

To get any response from the speed display it first must be calibrated. This is done by earthing the Greenwire (Grey plug pin 4). After the green wire is earthed you should see this, Press RED “SELECT” button to config-ure the over speed alarm.

enable Speed SenSor

SeleCt the CorreCt SiGnal tYpe

Press the Green button to “CHANGE” to either “Sinusoidal signal” or “Pulsed signal” and “SELECT”.This selection will depend on the type of speed signal input. If unsure continue to the next stage with either and determine by trial and error.

Calibrate pUlSeS per 10M

This stage will calibrate the speed of the vehicle. Setting an incorrect number will result in an incorrect displayed speed.

Ensure pulses per 10m are at zero before moving. Change the number of pulses by using the middle directional ‘mouse’ button; UP/DOWN to change the number dramatically and use LEFT/RIGHT to change the number slightly. Ballpark figures range from 100 to 500.

Start the vehicle and drive forwards precisely 10m. Note the number of pulses per 10m, lower pulses to zero and perform this test again until confident with the accuracy.

Press “SET” with the desired number of pulses.

note: If no pulses are detected the type of signal may not be correct (see Signal type above).

Speed diSplaYed? SeleCt and Set if deSired

KM/hr or Mile/hr? SeleCt and Set the deSired UnitS

do YoU reqUire Speed alarM?

An alarm can be sounded when the speed of the vehicle exceeds a desired limit.

Set deSired alarM Speed SUStain tiMe

Set the required time of the vehicle travelling over the speed limit needed until the buzzer sounds.Use the ‘mouse’ button to adjust, UP/DOWN and LEFT/RIGHT as explained above.

Set alarM Speed liMit

Use the ‘mouse’ button to adjust speed limit, UP/DOWN and LEFT/RIGHT.

YoU’re done! to operate YoUr Speed diSplaY and alarM:

Remove the Green wire from ground, tape up and hide away. This will return the speed display to normal op-eration.

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Calibration of Overspeed Alarm

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Start Up the Unit

For the seatbelt interlock to start up, it must have power (Red 12V and Black Earth), plus an earth on the Or-ange/White wire.

GroUnd the Green Wire to enter Calibration Mode

To get any response from seatbelt interlock it first must be calibrated. This is done by earthing the Green wire (Grey plug pin 4). After the green wire is earthed you should see this, Press RED “SELECT” button to configure buckle interlocks.

enable Seatbelt interloCK

do YoU reQUire an aUdible Seatbelt alarM?

do YoU reQUire a ViSUal Seatbelt diSplaY?

SeleCt hoW ManY SeCondS the Seatbelt iS diSenGaGed beFore the alarM/diS-plaY iS proMpted. (USe Middle bUtton)

YoU’re done! to operate YoUr Seatbelt interloCK:

Remove the Green wire from ground, tape up and hide away. This will return the monitor to normal operation. To ensure correct use by drivers the seatbelt must be disconnected before sitting on the seat.

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Calibration of Seatbelt Interlock

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MODULE INSTALLATION

Install monitor near the user’s line of sight, preferably near the rear vision mirror on the A-Pillar of a fork truck. Take care not to over tighten the mounting screws on the display case, as this can cause internal damage. Take care to route the harness cable out of harms way, preferably inside the A-pillar channel.

HArNESS INSTALLATION

Step 1. Battery Connection

RED WIRE = Permanent Fused 12VDC Supply at BatteryThe Red wire in the harness is permanent 12VDC supply to the unit. Connect this RED wire with a 5Amp fuse in series (provided in kit) to Battery positive terminal or 12V power supply. DO NOT install the fuse until the harness is fully installed and ready to test.

BLACK WIRE = Permanent Battery GroundConnect the Black wire to the battery ground terminal. If the vehicle has a Ground Isolation Switch, connect the Black Wire to the front of this switch to ensure correct functionality. Take care if you choose to get your Ground from a screw into the chassis of the vehicle, this device needs a very good, low resistance, ground source.

Step 2. On/Off Switching

ORANGE / WHITE WIRE = ON/OFF INPuT

The Fleet Weigh unit needs a negative switched input to tell it to turn on.The Orange/White wire is used to tell the unit to turn on and off. The unit needs a NEGATIVE switching signal. Some ideas include:

Method 1: Seat ActivationConnect the Orange/White wire to a normally open switch in the vehicles seat, and ground the common on the switch contact. When someone sits in the seat the Display will turn on, and turn off again when the person exits the vehicle.

Method 2: Key Switch ActivationConnect the Orange/White wire to Pin 87 on an Automotive Relay (Relay & Base Supplied in Kit). Connect a Battery Ground Feed to Pin 30 and Pin 85. Connect a Key Switch On/Igni-tion Feed to Pin 86. (Take care to ensure Positive on Coil Pin 86 and Negative on Coil 85 as the relay supplied is Diode Protected)

Step 3. Setup Mode Input

GREEN WIRE = SETuP Input

The Fleet Weigh unit needs the GREEN SETUP WIRE grounded to tell it to enter SETUP MODE.(See ‘Set Up’ page for Calibration instructions)The GREEN wire is used to enter Fleet Weigh SETUP mode. To enter SETUP mode, you ground the GREEN wire while the unit is ON. In nor-mal operation, tape the end of the green wire and keep it out of sight.

Optional Switched Cut-out / Inhibit relay Output

WHITE/ORANGE WIRE = INHIBIT RELAy DRIVER OuTPuT (SWITCHED GROuND OuTPuT)

The inhibit switched output is used to cut-out the vehicle’s ignition when/if required by the seat, buckle, pre-start check, and/or card swipe interlocks. You will not need this function for simple display requirements such as weigh scale readout.Connect the White/Orange wire to Pin 85 of the cut-out relay.Connect a permanent switched 12V supply to Pin 86 of the relay.Locate and cut the vehicle’s ignition crank wire and join each end of the cut wire to Pin 87 and Pin 30 normally open contacts of the relay.

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Wiring Installation

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Optional Weigh Scale Pressure Sensor Input (Pressure Sensor Connection)

GREY WIRE = WEIGht/PREssuRE sEnsoR InPut

You may use either a 2-wire Current Loop Pressure sensor or a 3-Wire Variable Voltage Output sensor with your Fleet Weigh unit.

Method A: If you plan to use a TWO WIRE 4..20 mA pressure sensor then:Make sure that the Grey wire enters PIN 2 of the Fleet Weigh Black 12 Way Connector. (Default configura-tion)Connect the GREY WIRE to the Signal pin on the sensor.Connect a switched power feed from the ignition key switch to the Positive pin on the sensor.

Method B: If you plan to use a THREE WIRE pressure sensor then:Make sure that the GREY wire enters PIN 1 of the Fleet Weigh Black 12 Way Connector (this is NOT the default configuration).Remember: Fleet Weigh can tolerate a maximum input signal of 18 VDC although you can use 5 VDC, 10 VDC or 12 VDC sensors.Connect the GREY WIRE to the Signal pin on the sensor.Connect a SWITCHED power and ground feed to the sensor per the sensors instructions.

Optional Speed Sensor Connection

PInK WIRE = sPEEd sIGnal InPut

You may use either a Three Wire Proximity sensor to detect gear tooth movement or your vehicle’s existing speed signal wire in order to obtain a speed signal input for Fleet Weigh.

Method A: If you plan to install a Hall Effect (Three Wire) proximity sensor then:Determine a suitable position to mount the sensor (typically the crown wheel).Mount within 1mm of the teeth.Connect the Pink wire to the signal wire of the sensor.Connect a SWITCHED ignition power and battery ground feed to the sensor per the sensors instructions.

Method B: If you plan to use the vehicle’s existing speed signal wire:Locate the speed signal wire on the vehicle.Tap the Pink wire onto the vehicle’s speed signal wire.Note: Not all signal types will be accepted by the Fleet Weigh unit – you can order separately a speed signal conditioner from Speedshield to make signals acceptable to Fleet Weigh.

Optional Seat Belt Buckle Interlock Connection

GREEn / BluE WIRE = sEat BElt BucKlE InPut

The Green/Blue wire in the harness is used for the Buckle interlock. This allows use of the Fleet Weigh seat belt interlockfunction.The seat belt buckle needs a Normally Open NEGATIVE switching signal.

Optional Proximity Card Reader Connection

WhItE/BluE = PRoxImItY caRd REadER communIcatIon lInE

REd/WhItE = PRoxImItY caRd REadER PoWER

A proximity card reader is used for user identification.This unit is supplied separately and is pre-wired with harness to ‘plug’ into Fleet Weigh 12 Way connectors. It is supplied with wiring dia-gram.

Serial Port Wires

The unit can be used for a multitude of functions, such as a pre-start check list, weigh scale, operator interlocks, speed display and alert. To set up advanced features the unit has an RS232 port that can be plugged into a Laptop computer. The Yellow / Black and wires represent RX and TX for a normal RS232 connection. This is not warranted for simple use of Fleet Weigh and these wires are not required.

Any Problems?

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MASS SENSOR

2 WIRE CURRENT SIGNAL

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CONNECT TO IGNITION "ON"

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CONNECT TO IGNITION "ON"

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3 WIRE VOLTAGE SIGNAL

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CONNECT TO IGNITION "ON"

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